Oscillating mirror assembly

Abstract

A mirror assembly for removably attaching a planar mirror to a rotating servomotor within an automated inspection machine is provided. The mirror assembly may comprise the planar mirror, the mirror having a lower end, an upper end, and a longitudinal axis. The mirror assembly may also comprise a first mirror holder comprising one of (a) three protrusions arranged in a triangular configuration and (b) three V-grooves. The mirror assembly also comprises a mirror mount including a first surface comprising the other of (a) the three protrusions and (b) the three V-grooves, and a second surface opposing the first surface. When fully assembled, the mirror mount is configured to removably hold the first mirror holder and the lower end of the planar mirror between the first and second surfaces such that the three protrusions are each received in a corresponding one of the V-grooves.

Description

OSCILLATING MIRROR ASSEMBLYFIELD OF THE DISCLOSURE

[0001] The present disclosure relates to an apparatus for removably attaching a planar mirror to a servomotor. More particularly, the present disclosure relates to a mirror assembly for attaching a planar mirror to a rotating servomotor of an automated product inspection machine in a manufacturing line.BACKGROUND OF THE DISCLOSURE

[0002] Manufactured products are preferably inspected for defects before being approved for final sale. Automated inspection machines may be used for this task. Such automated inspection machines may comprise a track or conveyor belt that carries manufactured products along a pre-configured path. A mirror mounted on a rotating or swiveling servomotor may be used to track and reflect images of individual products on this conveyor belt to an inspection camera, which can inspect each product as it passes. Because the mirror rotates to track an individual product as it passes, the conveyor belt need not pause to allow the inspection camera time to inspect each product. While this feature allows the i nspection machine to operate faster and more efficiently, automated inspection machines configured in this way require the mirror and servomotor to move in precise synchronization with the conveyor belt and with operation of the inspection camera. Tight tolerances are therefore required for the placement and orientation of the mirror on the rotating servomotor. Relatively minor deviances, such as a translation of the mirror relative to the servomotor by a fraction of a millimeter (e.g., by a few micrometers) in the x, y, or z direction, or rotation of the mirror relative to the servomotor by a fraction of a degree (e.g., a few thousandths of a degree) around the x-axis (0X), around the y-axis (0y), or around the z-axis (0Z), may impair the operation of the automated inspection machine or even render the machine inoperable.

[0003] Therefore, a need exists for mirror assemblies that can reliably and repeatably attach the mirror to the servomotor with a high degree of precision.SUMMARY

[0004] According to an exemplary embodiment of the present disclosure, a mirror assembly for removably attaching a planar mirror to a rotati ng servomotor is provided. The mirror assembly may comprise the planar mirror, the mirror having a lower end, an upper end, and a longitudinal axis extending from the lower end to the upper end. The mirrorassembly may further comprise a first mirror holder comprising one of (a) at least three protrusions arranged in a non-linear configuration and (b) at least three V-grooves. The mirror assembly may also further comprise (i) a mirror mount that includes a first surface comprising the other of (a) the protrusions and (b) the V-grooves, (ii) a second surface opposing the first surface, wherein the mirror mount is configured to removably hold the first mirror holder and the lower end of the planar mirror between the first and second surfaces such that the protrusions are each received in a corresponding one of the V-grooves, and (iii) one or more attachment features for releasably coupling the mirror mount to the rotating servomotor.

[0005] In one example, when the mirror assembly is fully assembled, rotation of the servomotor causes the mirror mount, the mirror holder, and the planar mirror to rotate around the longitudinal axis of the planar mirror.

[0006] In one example, the at least three protrusions consist of exactly three protrusions arranged in a triangular configuration, and the at least three V-grooves consist of exactly three V-grooves.

[0007] In one example, the three V-grooves may be oriented towards a common center.

[0008] In another example, the second surface comprises a fastener extending from the second surface that, when the lower end of the planar mirror and the mirror holder are held between the first and second surfaces, provides a seating force that biases the protrusions against the V-grooves.

[0009] In another example, the fastener comprises at least one of a screw-threaded fastener and a spring-loaded tip.

[0010] In another example, the mirror assembly further comprises a second mirror holder comprising a second mirror holder V-groove, wherein the mirror mount is configured to removably hold the first mirror holder, the planar mirror, and the second mirror holder between the first and second surfaces such that the fastener is received within the second mirror holder V-groove.

[0011] In another example, the second mirror holder V-groove may be oriented parallel to the longitudinal axis of the planar mirror.

[0012] In another example, the second mirror holder is integral with the planar mirror.

[0013] In another example, the first mirror holder is integral with the planar mirror.

[0014] In another example, at least a portion of each protrusion is sphere-shaped.

[0015] In another example, each protrusion may have a flat top portion.

[0016] In another example, one or more of the attachment points are screw interfaces.

[0017] According to another embodiment of the present disclosure, an automated inspection machine for inspecting manufactured products for defects is provided. The machine comprises a track configured to hold and transport manufactured products for inspection along a path shaped like a circular arc. The machine also comprises a servomotor positioned at the center of said circular arc, as well as a mirror assembly with a planar mirror, wherein the mirror assembly incorporates any or all of the design features discussed herein. The machine may also comprise an inspection camera configured to capture reflections in the planar mirror of products being transported along the track.

[0018] In one example, the manufactured products may be syringes.

[0019] According to yet another embodiment of the present disclosure, a method for assembling a mirror assembly is provided. The method may comprise providing: a planar mirror, the mirror having a longitudinal axis, a front surface and a rear surface; a first mirror holder having a rear surface and a front surface, the front surface comprising one of (a) at least three protrusions arranged in a non-linear configuration and (b) at least three V-grooves; and a mirror mount including: a first surface comprising the other of (a) the protrusions and (b) the V-grooves, and a second surface opposing the first surface. The method may further comprise positioning the planar mirror and the first mirror holder between the first surface and the second surface of the mirror mount such that the protrusions are each received in a corresponding one of the V-grooves; and providing a seating force that biases the protrusions against the V-grooves.

[0020] In one example, the method may comprise placing the rear surface of the first mirror holder against the front surface of the planar mirror before positioning the planar mirror and the first mirror holder between the first surface and the second surface of the mirror mount.

[0021] In one example, the planar mirror may define a through-hole and the first mirror holder may further comprise a flat tab and a pin protruding from the rear surface. In such examples, the method may further comprise aligning the first mirror holder with theplanar mirror by aligning the flat tab with a bottom surface of the planar mirror and by inserting the pin of the first mirror holder within the through-hole of the planar mirror.

[0022] In one example, providing the seating force may comprise inserting a screw- threaded fastener through the second surface of the mirror mount such that a tip of the fastener provides a biasing force that pushes against the rear surface of the planar mirror.

[0023] In one example, the method may comprise providing a second mirror holder having a rear surface defining a second mirror holder V-groove and a front surface. The method may also further comprise positioning the front surface of the second mirror holder against the rear surface of the planar mirror; and positioning the second mirror holder, the planar mirror, and the first mirror holder between the first and second surfaces of the mirror mount such that the tip of the screw-threaded fastener is received within the second mirror holder V-groove.

[0024] In one example, the method may further comprise attaching the mirror mount to a servomotor, such that rotation of the servomotor causes the mirror mount, the first mirror holder, and the planar mirror to rotate around the planar mirror’s longitudinal axis.

[0025] In some embodiments, an exemplary advantage of the disclosed mirror assembly is that it allows the planar mirror within to be reliably and repeatably positioned with respect to the servomotor of the automated inspection machine with a high degree of precision. For example, the mirror assembly allows the planar mirror to be removed (e.g., for cleaning, servicing, repair or replacement) and re-attached to the servomotor, such that the reattached planar mirror is positioned and oriented as closely as possible to the planar mirror’s original position and orientation, within relatively fight tolerances (e.g., with less than a fraction of a millimeter’s deviation in the x, y, or z directions, and / or with less than a fraction of a degree of rotation in the 0X, 0y, or 0Zdirections relative to the servomotor). This high degree of precision may be achieved without requiring the use of specialized alignment tools, and also helps avoid the need for a time-consuming and delicate recalibration of the automated inspection machine every time the planar mirror is removed and replaced. Other advantages will be recognized by those of ordinary skill in the art.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and will be better understood byreference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0027] FIG. 1 provides a top-down view of an automated inspection machine, according to some embodiments.

[0028] FIGS. 2A, 2B, 2C, 2D, 2E, and 2F show a fully assembled mirror assembly including a planar mirror for attachment to a servomotor of the automated i nspection machine, as viewed from multiple perspectives and according to some embodiments.

[0029] FIGS. 3 A and 3B show an exploded view of the mirror assembly from multiple perspectives, according to some embodiments.

[0030] FIG. 4 shows the planar mirror of the mirror assembly, according to some embodiments.

[0031] FIG. 5A shows a mirror mount of the mirror assembly from a perspective view, while FIGS. 5B, 5C, and 5D show the mirror mount from a top, left, and rear plan views respectively with aspects shown in phantom, according to some embodiments.

[0032] FIGS. 6A, 6B, 6C, and 6D show a first mirror holder of the mirror assembly from multiple perspectives, according to some embodiments.

[0033] FIG. 7 shows a second mirror holder of the mirror assembly from multi pie perspectives, according to some embodiments.

[0034] FIG. 8 provides a flowchart that depicts an exemplary method for assembling the mirror assembly, according to some embodiments.

[0035] FIGS. 9A-9C show an exploded view of a second embodiment of the mirror assembly from multiple perspectives, according to some embodiments.

[0036] FIGS. 10A-C show a mirror mount of the second embodiment of the mirror assembly from multiple perspectives, according to some embodiments.

[0037] FIG. 11 A shows a first mirror holder of the second embodiment of the mirror assembly from a perspective view, while FIGS. 1 IB, 11C, and 1 ID show the mirror holder from a bottom, front, and left plan views respectively with aspects shown in phantom, according to some embodiments.

[0038] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments ofthe invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.DETAILED DESCRIPTION

[0039] FIG. 1 provides a top-down view of an automated inspection machine 100 for inspecting manufactured products for defects. The machine 100 comprises a track 102 configured to hold and transport manufactured products 104 for inspection. As shown, at least a portion of the track 102 may be shaped like a circular arc 106. The track 102 may comprise a conveyor belt or moving track that moves products 104 in a pre-specified direction, such as in the direction of arrow 122. The manufactured products 104 may comprise any tangible product or intermediate component that may be transported on the track 102. For example, in one exemplary embodiment, the manufactured products may comprise syringes, vials, cartridges, , or other suitable objects.

[0040] The automated inspection machine 100 also comprises a housing or structure 108. In the embodiment depicted in FIG. 1, housing 108 is shaped like an octagon, although other shapes may also be used. The housing 108 comprises one or more transparent windows or openings 110 along its outer wall, illustratively one window 110 on each wall segment, to provide a view to the products 104 on track 102 from the inside of housing 108. The housing 108 also includes a mirror assembly 200 releasably coupled to a servomotor 112 positioned at the center of the circular arc 106. The servomotor 112 is configured to rotate the mirror assembly 200 back-and-forth in the direction of arrows 120, i.e., clockwise or counterclockwise around an axis that extends out of the page in FIG. 1.

[0041] The automated inspection machine 100 further comprises an inspection camera 116. In some embodiments, the camera 116 may be positioned between two of the windows 110 and pointed towards the mirror assembly 200. In operation, the camera 116 is configured to capture reflections from the mirror assembly 200 of products 104 being transported along track 102 outside of housing 108 in the direction of arrow 122. These captured reflections / images may be used by an electronic processor or displayed to an operator (not shown) to detect defects in the products 104. Exemplary defects may include particulates in drug product, improper container closure or seal, damaged or punctured needle shields, glass breakage, fractures or scratches, air bubbles exceeding tolerances, and the like.

[0042] While the camera 116 inspects a particular product 104, the servomotor 112 is configured to rotate the mirror assembly 200 to keep that product within the camera 116 ’ sfield of view. In some embodiments, each product 104 may be placed on (or secured within) an individual rotating platform (not shown) on track 102 that rotates each product 104 in the direction of arrow 124 as the product is being inspected. By rotating each product in the direction of arrow 124, the same side of product 104 is presented to mirror assembly 200 while the product is being inspected by camera 116. In this way, although the product 104 remains in constant motion on track 102 while it is being inspected, the rotation of product 104 on track 102, coupled with rotation of the mirror assembly 200 on servomotor 112, causes the image of product 104 captured by camera 116 to appear stationary for a brief moment while the product is being inspected. This allows the camera 116 to clearly inspect each individual product without requiring track 102 to constantly stop and start. When the camera 116 has finished inspecting the product 104, the servomotor 112 may then rotate the mirror assembly 200 to point towards another product to allow the camera 116 to inspect the next product. In this way, inspection machine 100 allows each product 104 to be inspected even while it is in motion, i.e., without having to stop track 102.

[0043] In some embodiments, the inspection machine 100 may inspect up to 600 products per minute. As a result, servomotor 112 may need to rotate mirror assembly 200 at high speed and in perfect synchronization with the movement of track 102, the rotation of the individual platforms on which products 104 are placed, and with the operation of inspection camera 116. In other words, the operation of inspection machine 100 relies on rapid and precise positioning of mirror assembly 200. This requires tight tolerances on the attachment and positioning of mirror assembly 200 relative to servomotor 112. Once inspection machine 100 has been calibrated, even very slight movements of mirror assembly 200 relative to servomotor 112, e.g., a translation in any direction (x, y, or z) of a fraction of a millimeter or a rotation of a fraction of a degree around the mirror assembly’s x-axis (0X), around the mirror assembly’s y-axis (0y), or around the mirror assembly’s z-axis (0Z) may impair the operation of inspection machine 100, or even render inspection machine 100 completely inoperable.

[0044] These tight tolerances pose a technical challenge, however, when it becomes necessary to remove mirror assembly 200 from servomotor 112 in order to clean, service, repair, or replace part or all of the mirror assembly 200. When mirror assembly 200 is removed and then re-attached, it may be difficult to position and orient mirror assembly 200 in its precise configuration prior to being removed. And if the re-attached mirror assembly 200 is positioned or oriented slightly differently from the way it was positioned / oriented before being removed, it will become necessary to re-calibrate machine 100. This re-calibration of the machine requires teaching or reprogramming the machine to accommodate for slight deviations in the way mirror assembly 200 is positioned on servomotor 112 and may be a complicated and time-consuming process. What is needed, therefore, is a way to release and then re-attach mirror assembly 200 to servomotor 112 in a secure and precise way, such that the re-attached mirror assembly 200 is positioned and oriented exactly as it was relative to servomotor 112 before being removed (e.g., within very tight tolerances for position and orientation). The mirror assembly 200 depicted and described below in relation to FIGS. 2A-7 is configured to midgate at least some of these technical problems.

[0045] FIGS. 2A-2F provide views of an exemplary fully assembled mirror assembly 200, while FIGS. 3A and 3B provide an exploded view of the mirror assembly 200. The mirror assembly 200 comprises a planar mirror 400, a mirror mount 500, a first mirror holder 600, and a second mirror holder 700. The mirror mount 500 is configured to be removably mounted to servomotor 112 such that, when the mirror assembly is fully assembled, rotation of the servomotor causes the mirror mount, the first and second mirror holders, and the planar mirror to rotate around the planar mirror’s longitudinal axis 408. Solely for ease of explication, FIGS. 2A-2F, 3A-3B, and all subsequent figures use the x, y, z directional system depicted by arrows 201. As used herein, references to the “up,” “upward,” or “upper” direction shall mean the positive z direction; references to the “down,” “downward,” or “lower” direction shall mean the negative z direction; references to the “front” or “forward” direction shall mean the positive x direction; references to the “back” or “rear” direction shall mean the negative x direction; references to the “left” direction shall mean the positive y direction; and references to the “right” direction shall mean the negative y direction.

[0046] The planar mirror 400 is depicted in greater detail in FIG. 4. As depicted in FIG. 4, the planar mirror 400 is generally shaped as a substantially flat panel having an upper end 402, a lower end 404, and a longitudinal axis 408 extending from the upper end to the lower end. The planar mirror has a front side 408 and a rear side 410. The mirror 400 is made of, or comprises, a reflective coating or material that allows it to reflect images of product 104 in sufficient detail and clarity for inspection camera 116 to detect defects in the product 104. Preferably, the mirror 400 is also made of or comprises a material that is sufficiently rigid and durable to withstand high-speed and high-frequency rotations by servomotor 112 about longitudinal axis 408. Suitable materials include glass or highly-polished metal. The mirror 400 also defines a through-hole 406 that runs from between the front and backsurfaces of mirror 400. In some embodiments, the hole 406 may be positioned close to the lower end 404 of the mirror 400.

[0047] Mirror assembly 200 also comprises a mirror mount 500, which is depicted in greater detail in FIGS. 5 A-5D. Mirror mount 500 includes a baseplate 502 shaped as a flat panel that defines five attachment points or features 504a-e. The attachment points 504a-e may comprise screw holes configured to receive bolts or screws for attaching the mirror mount 500 to the servomotor 112. Alternatively, or in addition, the attachment points may comprise snap-fit interfaces, latches, or other means for fastening the mirror mount 500 to the servomotor 112. Mirror mount 500 also comprises two walls 506 and 508 positioned on top of baseplate on opposite sides of mirror mount 500. Wall 506 has a first surface 507 and wall 508 has a second surface 509 parallel to the first surface 507 and that opposes the first surface 507. The first surface 507 defines three V-grooves 510a, 510b, and 510c. Each V-groove may be formed as a recessed i ndentation with a V-shaped cross-section, wherein two inwardly- sloping planar walls (e.g., 511 and 513) meet at a central seam (e.g., 515) at the middle of the V-groove. In some embodiments, seam 515 may have some measurable width such that the V-groove may not have a perfectly V-shaped cross-section; in other embodiments, seam 515 may simply be a corner where inwardly-sloping planar walls 511 and 513 meet. In some embodiments, each V-groove may also have an end wall (e.g., wall 514 for V-groove 510a; the walls for V-grooves 510b and 510c are depicted in FIG. 5 A but not separately enumerated) that is perpendicular to surface 507 and which closes one end of the V-groove, while the other end of the V-groove may be left open and unenclosed. The three V-grooves may be oriented towards a common center in that three lines extending the central seams 515 of the V-grooves would meet at a common point. Although the three V-grooves are depicted in the figures as having flat inwardly-sloping planar walls 511 and 513, in some embodiments the two walls 511 and 513 may exhibit a topology that is not perfectly planar or linear. For example, the inwardly- sloping walls 511 and 513 may alternatively be configured such that they are start out parallel to each other close to the surface 507 but converge towards each other as move deeper into wall 506. This convergence may be either a gradual or smooth transition (e.g., shaped like a U), or may take the form of one or more angular or step-like transitions in orientation, until the walls 511 and 513 meet at the central seam 515. To facilitate a secure attachment of planar mirror 400 to the servomotor, it is only necessary for walls 511 and 513 to exhibit an inwardly-converging V-shape at the points of contact between each V-groove and its corresponding protrusion 606a-c (as described herein). Asused herein, the term “V-groove” encompasses not only the V-grooves depicted in the figures, but also all of the aforementioned alternative configurations.

[0048] The second wall 508 may define a screw-hole 520 for accepting a fastener 550 (see FIG. 3A). The fastener 550 may comprise a screw-threaded fastener and / or a spring- loaded tip. As explained in further detail herein, the fastener 550 is configured to provide a seating force that keeps planar mirror 400, first mirror holder 600, and second mirror holder 700 firmly secured to the mirror mount 500 when fully assembled. The mirror mount may be made out of a suitably rigid and durable material, such as machined metal or hard plastic.

[0049] Mirror assembly 200 also comprises a first mirror holder 600, which is depicted in greater detail in FIGS. 6A-6D. First mirror holder 600 includes a generally rectangular body having a front side 602, a rear side 604, a top side 616, and a bottom side 614. The first mirror holder 600 may comprise three protrusions 606a-c positioned on the front side 602. In some embodiments, the three protrusions may be arranged in a triangular configuration. For example, such protrusions may be spaced apart in a non-linear fashion (i.e., they do not all fall on a single line) so as to form a triangle. Illustratively, protrusions 606b and 606c may be positioned equidistant from protrusion 606a to form an isosceles triangle. The angle formed between (a) the line between protrusions 606a and 606b and (b) the line between protrusions 606a and 606c may be greater than 90 degrees; this facilitates a triangular configuration that is shorter than it is wide (i.e., shorter in the z-dimension as compared to the y-dimension). This short and wide triangular configuration facilitates secure and repeatable attachment of planar mirror 400 to the mirror mount 500 (as described in further detail below), while making efficient use of space in the z-dimension so as not to obstruct the reflective surface of mirror 400. Each protrusion 606a-c may comprise a substantially sphere or ball-shaped knob that may, optionally, include a flattened top portion 608a-c. The first mirror holder 600 may also include a flat tab 610 disposed in the x-y plane flush with the bottom side 614 of the rectangular body and which protrudes from the rear side 604 of the body. Tab 610 is depicted as being shaped like a rectangle, but may also be shaped like any other shape, such as a semicircle or triangle. Finally, the first mirror holder 600 may also comprise a pin 612 that protrudes from the rear side 604 of the body. The pin 612 may be shaped like a cylinder as depicted in FIGS. 6A-6D, or may be shaped like any other shape (e.g., a triangular or rectangular prism, or like any other three-dimensional shape) corresponding to the shape of through-hole 406 in planar mirror 400.

[0050] Mirror assembly also comprises a second mirror holder 700, which is depicted in greater detail in FIG. 7. Second mirror holder 700 includes a generally rectangular body having a rear side 702, a front side 704, a top side 714, and a bottom side 716. The second mirror holder 700 may comprise a second mirror holder V-groove 706 positioned on the rear side 702 of the body. Like the previous three V-grooves 510a-c, the second mirror holder V- groove may be formed as a recessed indentation with a V-shaped cross-section, wherein two inwardly- sloping planar walls (708, 710) meet at a central seam 712 at the middle of the V- groove. The second mirror holder V-groove may also take the form of any of the alternative configurations for V-grooves previously discussed. The V-groove may be open at both ends as depicted in FIG. 7; alternatively, the V-groove may be closed at one end and open at the other end, or it may be closed at both ends. In some embodiments, the central seam 712 may be oriented parallel to the z-axis. In other embodiments, the central seam 712 may be oriented parallel to other directions, such as parallel to the y-axis.

[0051] FIG. 8 provides a flowchart 800 that illustrates the steps for assembling the mirror assembly 200 according to an exemplary embodiment. As best seen in FIGS. 3A-3B, mirror assembly 200 may be put together by first providing the aforementioned planar mirror 400, mirror mount 500, first mirror holder 600, and second mirror holder 700 (block 802). At block 804, an operator may attach the mirror mount 500 to the servomotor 112. This may be done, for example, by inserting a screw through each of the attachment points 504a-e to secure the mirror mount 500 to corresponding screw holes on servomotor 112 (not shown). At block 806, the rear surface 604 of first mirror holder 600 may be placed against the front surface 408 of planar mirror 400. When correctly positioned, the flat tab 610 may be positioned underneath and flush with (e.g., in contact with) the bottom side 404 of the planar mirror, while pin 612 may be inserted into hole 406 of mirror 400. At block 808, the front surface 704 of the second mirror holder 700 may be placed against the rear surface 410 of the planar mirror 400. At block 810, the two mirror holders 600, 700, with the planar mirror 400 sandwiched in-between them, may then be placed between the first surface 507 and the second surface 509 of mirror mount 500. When correctly positioned, the three protrusions 606a-c (including the flattened top portion 608a-c of each protrusion) of first mirror holder 600 may be received within a corresponding one of the three V-grooves 510a-c defined in the first surface 507 of mirror mount 500. When properly seated within a V-groove, each protrusion 606 will touch its V-groove at two points of contact: one point-of-contact on each inwardly- sloping planar wall (e.g., 511, 513) of the V-groove. Since there are threeprotrusions 606 each received within a V-groove 510, there will be a total of six points of contact between first mirror holder 600 and mirror mount 500. In some embodiments, the flat top portion of each protrusion may remain spaced apart from the central seam within each V- groove when assembled. Once the mirror holders and the planar mirror are properly positioned within mirror mount 500, a seating force may be provided that biases the three protrusions against the three V-grooves (block 808). This may be done by inserting the fastener 550 through screw-hole 520 of mirror mount 500 such that the dp of fastener 550 is received within the second mirror holder V-groove 712 in the rear face 702 of second mirror holder 700. The fastener 550 may be screwed, pushed, or otherwise configured to provide a seating force in the positive x direction that pushes the tip of fastener 550 against the second mirror holder V-groove 712. This seating force in turn pushes second mirror holder 700 against mirror 400, which pushes second mirror 400 against first mirror holder 600, which in turn pushes the three protrusions 606a-c into each of their corresponding V-grooves 510a-c of mirror mount 500. This seating force may be provided by screwing fastener 550 through screw-hole 520 to an appropriate torque, or by providing fastener 550 with a spring-loaded tip that provides the required seating force.

[0052] Because flat tab 610 is designed to be aligned flush with the bottom surface 404 of the planar mirror 400, and because the pin 612 is designed to be received within through-hole 406, the first mirror holder 600 may be precisely and reliably positioned with respect to planar mirror 400 by an operator with relative ease, without requiring the use of specialized alignment tools. Furthermore, because the three protrusions 606a-c of first mirror holder 600 are each received in a corresponding V-groove 51 Oa-c of mirror mount 500, the first mirror holder 600 may be precisely and reliably positioned with respect to mirror mount 500 by an operator with relative ease, again without requiring the use of specialized alignment tools. Accordingly, the aforementioned design features allow the planar mirror 400 to be precisely and reliably positioned with respect to mirror mount 500 without the use of specialized alignment tools.

[0053] Several design features in first mirror holder 600 and mirror mount 500 facilitate reliable positioning and alignment of first mirror holder 600 with respect to mirror mount 500. First, the three protrusions 606a-c are preferably arranged in a triangular configuration (as opposed to in a straight line). This triangular configuration means that when the three protrusions are properly secured, the first mirror holder 600, and in turn planar mirror 400, can more effectively resist translation in the x, y, or z direction, as well asrotation in the 0X, 0y, or 0Zdirections, relative to mirror mount 500. Second, each protrusion 606a-c is shaped like a ball or sphere with a flattened top. When each protrusion 606a-c is received within its corresponding V-groove 510a-c and a seating force is applied by fastener 550 in the positive x direction, the spherical shape of each protrusion interacts with the inwardly- sloping walls of each V-groove to guide each protrusion as deep as possible into the V-groove. This further facilitates precise and repeatable positioning of first mirror holder 600 with respect to mirror mount 500. Third, each of the three V-grooves 5 lOa-c in mirror mount 500 are preferably arranged such that they are oriented towards a common center, that is, lines extending the central seam 515 of each V-groove would meet at a common center point. This configuration also helps secure first mirror holder 600 from translating in the x, y, or z direction or rotating in the 0X, 0y, or 0Zdirections relati ve to mirror mount 500. Specifically, the orientation of the three V-grooves 510a-c towards a common center guides the protrusions 606a-c of first mirror holder 600 towards said common center point when a seating force (applied by fastener 550) is used to bias first mirror holder 600 against mirror mount 500. These features work together to both correctly position and orient first mirror holder 600 and planar mirror 400 with respect to mirror mount 500, and to also help the planar mirror 400 resist movement or rotation with respect to mirror mount 500 when the mirror assembly 200 is being moved by the servomotor 112.

[0054] While FIGS. 2A-7 depict one possible embodiment for a suitable mirror assembly, and FIG. 8 depicts one possible method for assembling the mirror assembly, other embodiments may also be used and are within the scope of this disclosure. For example, in some embodiments, the first mirror holder 600 may be integrated with planar mirror 400. This may be done by permanently attaching the first mirror holder 600 to planar mirror 400 (e.g., using screws or adhesive), or by manufacturing a single monolithic component that comprises a planar mirror and the three protrusions 606a-c. If planar mirror 400 and first mirror holder 600 are manufactured as a single monolithic component, flat tab 610, pin 612, and / or through-hole 406 may be omitted, since those components exist primarily to ensure first mirror holder 600 is correctly aligned with planar mirror 400. In addition, if planar mirror 400 and first mirror holder 600 are provided as a single component, block 804 of flowchart 800 in FIG. 8 may be omitted, and other blocks in flowchart 800 may be modified accordingly.

[0055] In a similar fashion, in some embodiments, the second mirror holder 700 may also be integrated with planar mirror 400. This may be done by permanently attaching thesecond mirror holder 700 to planar mirror 400, or by manufacturing a single monolithic component that comprises the planar mirror and the second mirror holder V-groove 706. In some embodiments, the second mirror holder 700 and the second mirror holder V-groove may be omitted entirely, and the fastener 550 may be configured to directly contact and push against the rear surface 410 of the planar mirror 400. In embodiments where the second mirror holder 700 is either integrated with planar mirror 400 or omitted entirely, block 806 in flowchart 800 may be omitted, and other blocks in flowchart 800 may be modified accordingly.

[0056] In some embodiments, the positions of the three protrusions 606a-c and the three V-grooves 510a-c may be reversed: for instance, the V-grooves 510a-c may be positioned on the front face 602 of first mirror holder 600, while the three protrusions 606a-c may be positioned on surface 507 of mirror mount 500. In such an embodiment, the three protrusions 606a-c may point in the negati ve x direction instead of the positive x direction as depicted in FIG. 3B and may be received in V-grooves positioned on the first mirror holder 600. The planar mirror 400 may include additional through-holes or attachment points that mate the mirror with first mirror holder 600 and / or second mirror holder 700.

[0057] In some embodiments, more than three protrusions and more than three V- grooves may be provided. For instance, a fourth, fifth, sixth, or even more protrusions may be added, each configured to be received in a corresponding V-groove, to further secure the planar mirror to the mirror mount. If more than three protrusions and V-grooves are provided, the protrusions should preferably be positioned non-linearly, i.e., they cannot be joined by a single line, and any polygon formed by joining all the protrusions using lines would have a non-zero area. Using three or more protrusions and V-grooves that are positioned non- linearly would help prevent the planar mirror from rotating around all three axes (i.e., 0X, 0y, 0X), whereas protrusions and V-grooves that are positioned linearly would leave the planar mirror vulnerable to rotation around the line along which the protrusions / V-grooves are placed. Other modifications to the disclosed mirror assembly may also be possible.

[0058] FIGS. 9A-1 ID depict a second embodiment 200’ of the mirror assembly. Just like mirror assembly 200 depicted in FIGS. 2A-7, mirror assembly 200’ is also configured to be removably mounted to servomotor 112. FIGS. 9A-9C provide an exploded view of mirror assembly 200’ from various perspectives. Similar to mirror assembly 200, mirror assembly 200’ also comprises planar mirror 400, fastener 550, and second mirror holder 700. Since planar mirror 400, fastener 550, and second mirror holder 700 are unchanged between thetwo embodiments, those components shall be referred to using the same reference numerals. Mirror assembly 200’ also comprises a modified first mirror holder 600’ (similar but not the same as first mirror holder 600) and a modified mirror mount 500’ (similar but not the same as mirror mount 500). Furthermore, mirror assembly 200’ comprises an adjustable threaded screw 902, washer 906, nut 908, and screw-threaded pins 904b, c. Each modified or additional component is described in further detail herein.

[0059] Modified mirror mount 500’ is depicted in greater detail in FIGS. 10A-C. Similar to mirror mount 500, mirror mount 500’ also includes a baseplate 502’ shaped like a flat panel and two walls 506’ and 508’ positioned on top of baseplate 502’ on opposite sides of mirror mount 500’. Baseplate 502’ differs from baseplate 502 in that in addition to the previously depicted and described five attachments points 504a-e, baseplate 502’ defines an additional sixth attachment point 504f’. The additional sixth attachment point 504f’ allows for a more reliable and secure attachment between mirror mount 500’ and servomotor 112 and is possible in this second embodiment because wall 506’ is smaller in size than wall 506, thus occupying less space on the top surface of baseplate 502’. This in turn allows for addition of the sixth attachment point 504f’.

[0060] Wall 506’ has a first surface 507’ and wall 508’ has a second surface 509’ parallel to the first surface 507’ and that opposes the first surface. However, whereas the first surface 507 of mirror mount 500 defines three V-grooves 510a, 510b, and 510c, first surface 507’ of mirror mount 500’ instead defines three screw holes 910a-c (as depicted in FIG. 10B). Screw holes 910b and 910c are configured to accept screw-threaded pins 912b and 912c. A front portion of said screw -threaded pins 912b and 912c include a screw thread configured to screw into screw holes 910b and 910c. A rear portion of said screw-threaded pins 912b and 912c include a protrusion 606b’ and 606c’. Said protrusions may be configured similar to previously-described protrusions 606a-c in that they comprise a substantially sphere or ball-shaped knob that may, optionally, include a flattened top portion. A middle part of said screw-threaded pins (between the aforementioned front and the rear portions) may comprise a flange 914b, 914c. The flange 914b, c may be shaped like a hexagonal nut as depicted or may take any other annular shape that protrudes radially outward (along the y-z plane) from a longitudinal axis of each screw-threaded pin that runs parallel to the x-axis.

[0061] Screw hole 910a is configured to accept an adjustable pitch pin 902. A front portion of said adjustable pitch pin 902 includes a screw-thread that is configured to screwinto washer 906 and nut 908. A rear portion of said adjustable pitch pin 902 includes a protrusion 606a’ that may also be configured similarly to previously-described protrusions 606a-c in that it comprises a substantially sphere or ball-shaped knob that may, optionally, include a flattened top portion. A middle portion of said adjustable pitch pin 902 (between the aforementioned front and rear portions) may comprise a flange 903. Again, the flange 903 may be shaped like a hexagonal nut as depicted or may take any other annular shape that protrudes radially outward (along the y-z plane) from a longitudinal axis of the adjustable pitch pin 902. When assembled (see, e.g., FIG. 10A), screw-threaded pins 912b-c are fully screwed into screw holes 910b, c such that flange 914b, c are flush with surface 507’. The adjustable pitch pin is also inserted into hole 910a but may or may not be inserted all the way such that flange 903 is flush with surface 507’. Instead, an operator may adjust the depth of insertion of adjustable pitch pin 902 into hole 910a by tightening or loosening the nut 908, and in this way easily adjust the position of the protrusion 606a’ along the x-axis. Adjusting the position of protrusion 606a’ along the x-axis in turn adjusts the pitch of planar mirror 400 when mirror assembly 200’ is fully assembled - translating the protrusion 606a’ in the negative x direction causes the planar mirror 400 to tilt in the negative x direction, whereas translating the protrusion 606a’ in the positive x direction causes the planar mirror 400 to tilt in the positive x direction. When mirror assembly 200’ is fully assembled, an operator can therefore torque nut 908 in order to easily adjust the pitch of planar mirror 400 in the positive or negative x direction.

[0062] Mirror assembly 500’ also comprises a modified first mirror holder 600’, which is depicted in greater detail in FIGS. 11 A-D. Just like first mirror holder 600, first mirror holder 600’ includes a generally rectangular body having a front side 602’, a rear side 605’, a top side 616’ and a bottom side 614’. However, whereas first mirror holder 600 comprises three protrusions 606a-c positioned on the front side 602, first mirror holder 600’ instead comprises three V-grooves 510a-c’ on the front side 602’. The V-grooves 510a-c’ may be configured similarly to previously-described V-grooves 510a-c in that each V-groove may be formed as a recessed indentation with a V-shaped cross-section, wherein two inwardly- sloping planar walls meet at a central seam in the middle of the V-groove. The V- grooves 510a-c’ may also take any of the alternative embodiments described above. Similar to V-grooves 510a-c, the three V-grooves 510a-c’ may be oriented towards a common center in that three lines extending the central seam of each V-groove would meet at a common point. Similar to first mirror holder 600, the first mirror holder 600’ may also include a flattab 610’ disposed in the x-y plane flush with the bottom side 614’ of the rectangular body and which protrudes from the rear side 604’ of the body. Tab 610’ is depicted as being shaped like a rectangle, but may also be shaped like any other shape, such as a semicircle or triangle. Finally, the first mirror holder 600’ may also comprise a pin 612’ that protrudes from the rear side 604’ of the body. The pin 612’ may be shaped like a cylinder as depicted in FIGS. 11 A- D, or may be shaped like any other shape (E.g., a triangular or rectangular prism, or like any other three-dimensional shape).

[0063] The steps included in the flowchart 800 of FIG. 8 are also applicable for assembling the mirror assembly 200’. As best seen in FIGS. 9A-C, mirror assembly 200’ may be put together by first providing the aforementioned planar mirror 400, mirror mount 500’, first mirror holder 600’, and second mirror holder 700’ (block 802). At block 804, an operator may attach the mirror mount 500’ to the servomotor 112. This may be done, for example, by inserting a screw through each of the attachment points 504a-f’ to secure the mirror mount 500’ to corresponding screw holes on servomotor 112 (not shown). At block 806, the rear surface 604’ of first mirror holder 600’ may be placed against the front surface 408’ of planar mirror 400. When correctly positioned, the flat tab 610’ may be positioned underneath and flush with (e.g., in contact with) the bottom side 404 of the planar mirror, while pin 612’ may be inserted into hole 406 of mirror 400. At block 808, the front surface 704 of the second mirror holder 700 may be paced against the rear surface 410 of the planar mirror 400 such that the bottom side 716 of the second mirror holder 700 is aligned with the bottom side 404 of the planar mirror. At block 808, the two mirror holders 600’, 700, with the planar mirror 400 sandwiched in-between them, may then be placed between the first surface 507’ and the second surface 509’ of mirror mount 500’. When correctly positioned, the three protrusions 606a-c’ (including the flattened to portion of each protrusion) on the screw-threaded pins 912b and 912c and adjustable pitch pin 902 may be received within a corresponding one of the three V-grooves 510a-c’ defined in the front face 602’ of modified first mirror holder 600’. Once the mirror holders and the planar mirror are properly positioned within mirror mount 500’, a seating force may be provided that biases the three protrusions against the three V-grooves (block 810). This may be done by inserting the fastener 550 through screwhole 520 of mirror mount 500 such that the tip of fastener 500 is received within the second mirror holder V-groove 712 in the rear face 702 of second mirror holder 700. The fastener 550 may be screwed, pushed, or otherwise configured to provide a seating force in the positive x direction that pushes the tip of fastener 550 against the second mirror holder V-groove 712. This seating force in turn pushes second mirror holder 700 against mirror 400, which pushes second mirror 400 against first mirror holder 600’, which in turn pushes the three protrusions 606a-c’ into each of their corresponding V-grooves 510a-c’ of mirror mount 500’. This seating force may be provided by screwing fastener 550 through screw -hole 520 to an appropriate torque, or by providing fastener 550 with a spring-loaded tip that provides the required seating force.

[0064] The terms "first", "second", "third" and the like, whether used in the description or in the claims, are provided for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances (unless clearly disclosed otherwise) and that the embodiments of the disclosure described herein are capable of operation in other sequences and / or arrangements than are described or illustrated herein.

[0065] While this invention has been described as having exemplary designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.

Claims

WHAT IS CLAIMED IS:

1. A mirror assembly comprising: a planar mirror having a lower end, an upper end, and a longitudinal axis extending from the lower end to the upper end; a first mirror holder comprising one of (a) at least three protrusions arranged in a non-linear configuration and (b) at least three V-grooves; and a mirror mount including: a first surface comprising the other of (a) the protrusions and (b) the V-grooves, a second surface opposing the first surface, wherein the mirror mount is configured to removably hold the first mirror holder and the lower end of the planar mirror between the first and second surfaces such that the protrusions are each received in a corresponding one of the V-grooves, and one or more attachment features for releasably coupling the mirror mount to a servomotor.

2. The mirror assembly of claim 1, wherein when the mirror assembly is assembled, a rotation of the servomotor causes the mirror mount, the first mirror holder, and the planar mirror to rotate together around the longitudinal axis of the planar mirror.

3. The mirror assembly of claim 1, wherein the at least three protrusions consist of exactly three protrusions arranged in a triangular configuration, and the at least three V-grooves consist of exactly three V-grooves.

4. The mirror assembly of claim 3, wherein the three V-grooves are oriented towards a common center.

5. The mirror assembly of any one of claims 1-4, wherein the mirror mount comprises a fastener extending from the second surface that, when the lower end of the planar mirror and the mirror holder are held between the first andsecond surfaces, provides a seating force that biases the protrusions against the V-grooves.

6. The mirror assembly of claim 5, wherein the fastener comprises at least one of a screw-threaded fastener and a spring-loaded tip.

7. The mirror assembly of any one of claims 5-6, further comprising a second mirror holder comprising a second mirror holder V-groove, wherein the mirror mount is configured to removably hold the first mirror holder, the planar mirror, and the second mirror holder between the first and second surfaces such that the fastener is received within the second mirror holder V-groove.

8. The mirror assembly of claim 7, wherein the second mirror holder V-groove is oriented parallel to the longitudinal axis of the planar mirror.

9. The mirror assembly of any one of claims 7-8, wherein the second mirror holder is integral with the planar mirror.

10. The mirror assembly of any one of claims 1-9, wherein the first mirror holder is integral with the planar mirror.

11. The mirror assembly of any one of claims 1-10, wherein at least a portion of each protrusion is sphere-shaped.

12. The mirror assembly of claim 11, wherein each protrusion has a flat top portion.

13. The mirror assembly of any one of claims 1-12, wherein the one or more attachments features are screw interfaces.

14. An automated inspection machine for inspecting manufactured products for defects, the machine comprising: a track configured to hold and transport manufactured products for inspection along a path shaped like a circular arc; a servomotor positioned at the center of said circular arc; the mirror assembly of any one of claims 1-13 releasably attached to the servomotor; andan inspection camera configured to capture reflections in the planar mirror of products being transported along the track.

15. The automated inspection machine of claim 14, wherein the manufactured products are syringes.

16. A method for assembling a mirror assembly, the method comprising: providing: a planar mirror, the mirror having a longitudinal axis, a front surface and a rear surface, a first mirror holder having a rear surface and a front surface, the front surface comprising one of (a) at least three protrusions arranged in a non-linear configuration and (b) at least three V-grooves, and a mirror mount including: a first surface comprising the other of (a) the protrusions and (b) the V-grooves, and a second surface opposing the first surface; positioning the planar mirror and the first mirror holder between the first surface and the second surface of the mirror mount such that the protrusions are each received in a corresponding one of the V-grooves; and providing a seating force that biases the protrusions against the V-grooves.

17. The method of claim 16, wherein the at least three protrusions consist of exactly three protrusions arranged in a triangular configuration, and the at least three V-grooves consist of exactly three V-grooves oriented towards a common center.

18. The method of any one of claims 16-17, further comprising placing the rear surface of the first mirror holder against the front surface of the planar mirror before positioning the planar mirror and the first mirror holder between the first surface and the second surface of the mirror mount.

19. The method of any one of claims 16-18, wherein the planar mirror defines a through-hole and the first mirror holder further comprises a flat tab and a pin protruding from the rear surface, the method further comprising: aligning the first mirror holder with the planar mirror by aligning the flat tab with a bottom surface of the planar mirror and by inserting the pin of the first mirror holder within the through-hole of the planar mirror.

20. The method of any one of claims 16-19, wherein providing the seating force comprises inserting a screw-threaded fastener through the second surface of the mirror mount such that a tip of the fastener provides a biasing force that pushes against the rear surface of the planar mirror.

21. The method of claim 20, further comprising providing a second mirror holder having a rear surface defining a second mirror holder V-groove and a front surface, the method further comprising: positioning the front surface of the second mirror holder against the rear surface of the planar mirror; and positioning the second mirror holder, the planar mirror, and the first mirror holder between the first and second surfaces of the mirror mount such that the tip of the screw- threaded fastener is received within the second mirror holder V-groove.

22. The method of any one of claims 16-21, further comprising attaching the mirror mount to a servomotor, such that rotation of the servomotor causes the mirror mount, the first mirror holder, and the planar mirror to rotate around the planar mirror’s longitudinal axis.

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